Residual Stresses of Small-Bore Butt-Welded Piping Measured by Quantum Beam Hybrid Method

Cracks due to stress corrosion cracking in stainless steels are becoming a problem not only in boiling water reactors but also in pressurized water reactor nuclear plants. Stress improvement measures have been implemented mainly for large-bore welded piping, but in the case of small-bore welded piping, post-welding stress improvement measures are often not possible due to dimensional restrictions, etc. Therefore, knowing the actual welding residual stresses of small-bore welded piping regardless of reactor type is essential for the safe and stable operation of nuclear power stations, but there are only a limited number of examples of measuring the residual stresses. In this study, austenitic stainless steel pipes with an outer diameter of 100 mm and a wall thickness of 11.1 mm were butt-welded. The residual stresses were measured by the strain scanning method using neutrons. Furthermore, to obtain detailed residual stresses near the penetration bead where the maximum stress is generated, the residual stresses near the inner surface of the weld were measured using the double-exposure method (DEM) with hard X-rays of synchrotron radiation. A method using a cross-correlation algorithm was proposed to determine the accurate diffraction angle from the complex diffraction patterns from the coarse grains, dendritic structures, and plastic zones. A quantum beam hybrid method (QBHM) was proposed that uses the circumferential residual stresses obtained by neutrons and the residual stresses obtained by the double-exposure method in a complementary use. The residual stress map of welded piping measured using the QBHM showed an area where the axial tensile residual stress exists from the neighborhood of the penetration bead toward the inside of the welded metal. This result could explain the occurrence of stress corrosion cracking in the butt-welded piping. A finite element analysis of the same butt-welded piping was performed and its results were compared. There is also a difference between the simulation results of residual stress using the finite element method and the measurement results using the QBHM. This difference is because the measured residual stress map also includes the effect of the stress of each crystal grain based on elastic anisotropy, that is, residual micro-stress.